Download RS6-R8-P6-P8-P10 OPERATING INSTRUCTIONS.cdr

RS6 - R8 - P6 - P8 - P10
SUBMERSIBLE PUMPS
Operating Instructions
Contents
1.0
1.1
1.2
1.3
1.4
2.0
2.1
2.2
3.0
3.1
3.2
3.3
4.0
4.1
4.2
4.3
5.0
5.1
5.2
5.3
6.0
6.1
6.2
6.3
6.4
6.5
6.6
7.0
8.0
8.1
8.2
8.3
8.4
9.0
9.1
10.0
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
11.0
11.1
11.2
Page
General information
1
General
1
Symbols
1
Designation
2
Pumped liquids
2
Safety instructions
2
Unauthorised modification and manufacture of spare parts 3
Statement of non-liability
3
Description of the product
3
Technical specification P6 – P8 – P10
3
Technical specification RS6 – R8
4
Mounting arrangements
4
Transport and Intermediate storage
5
Delivery
5
Handling
5
Intermediate storage
6
Assembling the motor and pump
7
Checking of liquid in motor
7
Shaft rotation test
7
Assembly
8
Installation
8
Hydraulic installation
8
Installation site specifications
9
General advice for installation
9
Vertical installation of pre-assembled pump unit
11
Horizontal installation of pre-assembled pump unit
13
Electrical Connection
13
Start-Up
14
Maintenance/Servicing
15
Pump unit
15
Electrical system
15
Removal
15
Notes of disassembly and assembly
15
Operating problems and their elimination
16
Checking of motor and cable
17
Sectional drawings with parts list
18
Submersible pump RS6
18
Submersible pump R8
19
Submersible pump P642
20
Submersible pump P6 (with thread connection)
21
Submersible pump P6 (with flange connection)
22
Submersible pump P8 (with thread connection)
23
Submersible pump P8 (with flange connection)
24
Submersible pump P8170
25
Submersible pump P8250
26
Protocols
27
Installation protocol
27
Commissioning protocol
28
GB
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
Thank you for purchasing a quality K.S.P. product. The present instructions will assist you
during commissioning and operation of the pump. These operating instructions contain
fundamental information and precautionary notes.
These Instructions must always be kept close to the product’s operating
location or directly with the product.
These instructions should be read prior to installing, operating, using and
maintaining the equipment in any region worldwide. The equipment must not
be put into service until all the conditions relating to safety, noted in the
instructions, have been met.
1.0 General information
1.1 General
This pump has been developed in accordance with state-of-the-art technology; the unit is
produced with great care and commitment to continuous quality control, utilising sophisticated
quality techniques, and safety requirements. These operating instructions are intended to
facilitate familiarisation with the pump and its designated use. The manual contains important
information for reliable, proper and efficient operation. Compliance with the operating
instructions is of vital importance to ensure reliability and a long service life of the pump and to
avoid any risks. The instructions may not take into account local regulations; ensure such
regulations are observed by all, including those installing the product. This pump must not be
operated beyond the limit values specified in the technical documentation for the medium
handled, capacity, speed, density, pressure, temperature and mo tor rating. Make sure that
operation is in accordance with the instructions laid down in this manual or in the contract
documentation. These instructions describe the procedures to be used for fitting, operation and
maintenance of standard submersible pumps.
1.2 Symbols
These User Instructions contain specific safety markings where non-observance of an
instruction would cause hazards. The specific safety markings are:
This symbol indicates safety instructions where non-compliance would affect
personal safety and could result in loss of life.
This symbol indicates electrical safety instructions where non-compliance will involve
a high risk to personal safety or the loss of life.
1
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
This symbol indicates safety instructions where non-compliance will involve some
DANGER risk to safe operation and personal safety and would damage the equipment or
property.
1.3 Designation
R S 6 18 /12
RS618/12
R
= Radial submersible pump - Pompe immergée radiale
S
= Submersible pump with cast-iron diffusers and Noryl impellers - Pompe immergée avec diffuseurs de fonte et roues Noryl
6
= Nominal diameter in inches - Diamètre nominal en pouces
18
= Identification impeller number - Numero identification roue
/12
= Number of stages - Nombre d'étages
P 6 45 /10
P645/10
P
= Mixed flow submersible pump - Demi-axiale pompe immergée
6
= Nominal diameter in inches - Diamètre nominal en pouces
45
= Identification impeller number - Numero identification roue
/10
= Number of stages - Nombre d'étages
R 8 40 /15
R840/15
R
= Radial submersible pump - Pompe immergée radiale
8
= Nominal diameter in inches - Diamètre nominal en pouces
40
= Identification impeller number - Numero identification roue
/15
= Number of stages - Nombre d'étages
1.4 Pumped liquids
Standard submersible pumps serve to transport cold clean water under normal operating
conditions. Pumped liquids must be: clean, thin, free of solid particles or fibres, compatible with
pump components and materials. The maximum sand content of the water must not exceed
manufacturer’s recommendations. A larger sand content will reduce the life of the pump and
increase the risk of blocking. When pumping liquids with a density higher than that of water,
motors with correspondingly higher outputs must be used. Other uses or operating purposes
must be agreed upon with the manufacturer.
2.0 Safety instructions
These operating instructions contain fundamental information which must be complied with
during installation, operation and maintenance. Therefore this operating manual must be read
and understood both by the installing personnel and the responsible trained
personnel/operators prior to installation and commissioning, and it must always be kept close
to the location of operation of the machine/unit for easy access. The operator is responsible for
ensuring that all maintenance, inspection and installation work be performed by authorised,
qualified specialist personnel who are thoroughly familiar with the manual. If the personnel in
question do not already possess the necessary knowledge and skill, appropriate training and
instruction must be provided.Work on the machine must be carried out only during standstill.
The shutdown procedure described in the manual for taking the machine out of service must
be adhered to without fail.
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
2
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
DANGER The unit may only be operated by trained personnel, only in a completely
assembled condition, and with a completely filled and immersed pump unit.
All work on the electrical system may only be performed by qualified
electrician!
- Guards for movable parts (e.g. coupling) must not be removed from the machine while it is in
operation.
- Danger from electric energy must be eliminated (for details see e.g. the regulations of the
VDE and the local power supply companies).
Before maintenance and repair work, the motor of the pump unit must first be
completely separated from the power supply.
Pumped liquids that may be hazardous to health must be decontaminated prior
to maintenance.
2.1 Unauthorised modification and manufacture of spare parts
Modifications or alterations of the machine are only permitted after consultation with the
manufacturer. Original spare parts and accessories authorised by the manufacturer ensure
safety.
2.2 Statement of non-liability
By not heeding this documentation, product liability is rendered void.
3.0 Description of the product
3.1 Technical specification P6 - P8 - P10
KSP submersible pumps are multistage centrifugal types which operate below water level and
driven by an electric submersible motor. KSP submersible pumps Series P6 – P8 – P10
represent the strength and consistence towards pumping instances. Lightweight, low operating
and maintenance cost are some advantages among others. KSP submersible pumps are welltested machines, ideal for raising capacities up to 400m3/h and delivery heads up to 600m.
Bowls are provided of sturdy cast-iron with incorporated sleeve bearings for shaft protection.
Closed-type impellers made of high quality bronze are fastened with a split, tapered bushing
that locks impeller firmly in place. Valve casing of cast-iron incorporates a non-return valve of
bronze for preventing the hydraulic system of water hammering. Suction casing is made of high
strength cast-iron with a fitted stainless steel strainer which facilitates the smooth approach of
fluid to the suction impeller and restricts the entry of foreign objects. KSP submersible pumps can
be totally offered of bronze. All mounting dimensions are in accordance with NEMA standards.
3
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
3.2 Technical specification RS6 – R8
KSP submersible pumps Series RS6-R8 are characterized by a high number of stages with a
short length, able to deal in great depths of installation and high heads. KSP submersible
pumps are well-tested machines, ideal for raising capacities up to 70m3/h and delivery heads
up to 580m. Bowls are provided in high strength cast-iron. Series R8 bowls incorporate steel
bearing for shaft protection. Closed-type radial impellers are made of bronze for Series R8 and
of reinforced Noryl for the Series RS6. Valve casing of both series is made of cast-iron and
incorporates a bronze, non-return valve with stainless steel spring preventing from water
hammering and friction losses. Series R8 valve casing is integrated steel bearing which
prevents from malfunction when the pump shaft begins to whip. Suction casing is made of
cast-iron. A steel bearing is fitted, specifically designed to handle loading presenting in a
pumping application and prevents shaft misalignment. An external stainless steel strainer
reduces the amount of sediment that can enter in the pump. All mounting dimensions are in
accordance with NEMA standards.
3.3 Mounting arrangements
Except the pump types RS6, P642 and P8250, the following pump types can be offered either
with thread or flange connection: P6 – P8 – P10.
Figure 3-1: Thread
connection
Figure 3-2: Flange
connection
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
4
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
4.0 Transport and Intermediate storage
4.1 Delivery
These submersible pumps are supplied from the factory in proper packing. The unit must be
taken out of its packaging immediately upon receipt and checked for possible damage,
completeness and correctness. If damage has been determined, notify the carrier immediately.
During unpacking and prior to installation, care must be taken when handling the pump to
ensure that misalignment does not occur due to bending.
4.2 Handling
DANGER
Take special care when handling the pump unit. Avoid hitting the pump
against massive objects during handling and transport!
Examples for correctly transporting pump and motor:
Figure 4-1: Horizontal
proper handling
Figure 4-2: Improper
handling
5
Figure 4-3: Vertical
proper handling
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
Due to the danger of sagging, overlong pump units must be supported by an
DANGER auxiliary carrier (U or H carrier) when lifted into the vertical position. This
carrier may only be removed after the pump unit is hanging vertically from the
crane or lifting block. (See Figure 4-4.)
DANGER For transport, ensure that the hoist has an adequate carrying capacity.
DANGER Under no circumstances must the power cables be used for lifting or moving
the motor.
Figure 4-4
4.3 Intermediate storage
-
Storage location must be free of dust, dry and protected against heat and frost.
-
The pump should not be exposed to direct sunlight. If the pump has been unpacked, it
should be stored horizontally, adequately supported or vertically, secured appropriately in
this position to prevent tipping over.
-
For storage between one and three months, it is recommended that the shaft of the unit be
turned at intervals. On pump units where this is not possible, the pump and motor must be
separated.
-
Long-time storage of more than 3 months: preservation required!
-
The leads of the power supply cables must be protected from moisture. Also be careful that
the power supply cables are not bent during storage.
Storage temperatures:
a) +50 to -25 °C (+122 to -13 °F) for units with unfilled motors.
b) +50 to 0 °C (+122 to +32 °F) for units with water-filled motors without antifreeze.
-
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
6
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
5.0 Assembling the motor and pump
5.1 Checking of liquid in motor
The submersible motors are factory-filled with clean water.
The level of the liquid in the motor must be checked and the motor must be
refilled, if required. Use clean water.
Refilling of liquid is carried out as described below.
The filling hole for motor liquid is placed in the top of the motor.
Filling procedure:
1. Place the motor vertically with the top of the motor upwards, see fig. 5.1
2. Unscrew the plug 1 and place a funnel in the hole.
3. Pour water into the motor until the motor liquid inside the motor starts running out at
plug 2.
4. Remove the funnel and refit the plugs 1 and 2.
1
2
Figure 5-1: Correct way to fill
the motor
Figure 5-2: Incorrect way to
fill the motor
Figure 5-3: Incorrect way to fill the motor
5.2 Shaft rotation test
Check the motor shaft for smooth rotation before assembly with the pump. It runs freely after
overcoming static friction.
7
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
5.3 Assembly
1. Remove the motor’s shaft
. guard
2. Remove pump’s strainer.
3. Make sure that the mating surfaces of the parts to be connected are free of dust and
dirt.
4. Align pump and motor shafts to each other and join pump and motor together.
5. Bolt motor and pump together and tighten the fastening screws crosswise, as
specified.
6. Replace pump’s strainer.
Figure 5-4: Vertical assembly
Figure 5-5: Horizontal assembly
6.0 Installation
6.1 Hydraulic installation
A typical design for a water supply system is shown in Figure 6.1. As this shows a basic
arrangement, the actual layout must be adapted to local conditions.
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
8
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
8 9 10
water level
7
6
5
4
3
minimum 1m
2
1
2
3
4
5
6
7
8
9
10
Clearence area for silt disposit
Submersible motor
Submersible pump
Non-return valve
Rising main
Cable clip
Supporting claml/well head
Water meter
Manometer
Isolating valve
1
Figure 6-1: Vertical installation, pump without shroud
6.2 Installation site specifications
-
Make sure that transporting the pump unit or its components to or from the installation site
is possible without any hazard.
Appropriate lifting gear and attachment devices must be available.
6.3 General advice for installation
6.3.1 Vertical installation
The following criteria must be taken into account to determine the installation position and
depth:
- Vertical fitting in a well above the filter line, so that a perfect flow is guaranteed along
the external motor surface.
9
-
Sufficient water cover.
-
A static water level at least 2m above the pump exit.
-
A dynamic water level above the suction housing, taking into account the required
NPSH value (see pump characteristic) for the pump.
-
Flow rate (see pump characteristic).
-
Access to the inlet strainer must be unblocked.
-
Make sure that the well is free from mud and sand deposits.
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
-
Ensure that the line voltage (measured between two phases) is equal to the motor
voltage according to the rating plate.
-
The maximum permissible voltage fluctuation can be seen in motor label. Greater
voltage and frequency fluctuations must be given in the order and confirmed by the
factory.
-
It must be ensured that the well diameter is large enough down to the fitting depth, so
that the pump unit can be fitted without difficulties.
-
When pump units are installed in narrow wells the steel pipes or hose lines, will need to be
centralised to prevent them from touching the wall of the well which could cause damage to
any cables fastened to them.
6.3.2 Horizontal installation
-
When the pump is installed horizontally, the discharge port should never fall below the
horizontal plane, see fig. 6.2.
Figure 6-2: Positional requirements
Allowed
Not allowed
It is recommended fitting a motor cooling jacket if the pump is installed in a
horizontal position.
-
During operation, the lowest water level must be such that the pump does not draw in any
air.
The pump is not suitable for completely draining the tank.
It is recommended cleaning the suction strainer and the motor surface if they are heavily
soiled.
6.3.3 Pumps with shrouds
Motor cooling/sand protection jacket
Serves to increase the flow velocity on the motor surface to enhance the heat dissipation in the
following cases:
- too high liquid temperature.
- too low flow velocity on the motor surface.
- deposits on the motor surface due to the liquid composition.
- water inflow in the well above the motor.
- protects the pump against increased sand catchments.
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
10
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
Figure 6-3: Cooling jacket
6.4 Vertical installation of pre-assembled pump unit
Heed the following factors when selecting the hoisting device:
-
weight of the unit including the cables
-
weight of the rising main
-
for removal: additional weight of the water filling in the rising main
To detect cable damage s right away, measure the resistance at regular intervals during
lowering.
The cable must be carefully rolled up or laid out during installation (and also during removal of
the unit) to prevent damages to material and injuries to persons caused by the cable being
pulled inevitably if a pump should drop into the well.
DANGER Make sure that no one steps into the rolled-up cable loop.
Long pump units must be supported with a reinforcement to avoid sagging
during rising. Remove the reinforcement only when the unit is vertically
suspended from the crane or tackle.
1. Mount the first length of the ascending pipe, which should not be longer than
0.5 m onto the assembled pump unit.
2. Fasten the power supply cables and, if necessary, the control lines and /or
instruments lead with clamps onto the ascending pipe.
3. Attach a “fitting bracket” (3) beneath the ascending pipe flange or sleeve and
hang the complete unit from a suitable hoist.
11
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
1. Lower the pump unit into the well until the fitting bracket is resting on the well
pipe or well head.
2. Attach the next length of the ascending pipeline (4). Secure the power supply
cables and, if necessary, the control lines and/or instrument lead approx 0.5 m
above the flange with a clamp.
3. Connect a second fitting bracket (6) beneath the upper flange or beneath the
sleeve with screwed pipes. Hang the unit onto the hoist with the upper fitting
bracket, rise a bit, release the lower fitting bracket and sink the unit slowly into
the well.
DANGER Do not let the pump slip through the bracket!
When lowering the unit, proceed so that the power supply cable is neither squeezed nor
scraped. In order to protect the power supply cables, we recommend lining the well head at the
entry point of the power supply cable into the well pipe with a rubber sheet and feed it into the
well shaft using a cable roller (see Fig. 6.4). During the lowering, the unit must always hang
freely and must not become wedged in the well casing-tube. One control possibility: the pump
can be rotated freely. Attach a second cable clamp about 0.5 m beneath the upper
flange/sleeve. Lower the unit far enough for the fitting bracket to sit on the well head and then
screw on the next piece of the ascending pipeline. If needed, attach a cable clamp every 3 m of
pipe length. Install the remaining riser pipes as described from point 2. to 6.
For especially narrow and deep wells, the insulating measurements should be
repeated, during installation process, in order to be able to determine possible
damage to the power supply cables in time.
Ascending pipeline (5)
Fitting bracket (6)
Cable roller
Fitting bracket (3)
Rubber sheet
Power supply cable
Cable clamp
Well casing-tube
Figure 6-4
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
12
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
6.5 Horizontal installation of pre-assembled pump unit
Pumps may only be installed in a horizontal position if this has been permitted
by the manufacturer.
- Using an appropriate hoisting device, lower the pump unit onto the prepared support in the
basin after topping up the motor (as for vertical installation).
- Secure the pump unit on the steel supports.
- Support the pump unit in its centre of gravity. Several supports are required for pumps with
many
stages.
- Heed the minimum water level. The minimum water level above the pump must be
dimensioned in dependence of the capacity and if it is used a motor cooling shroud.
6.6 Electrical Connection
Before starting work on the pump, make sure that the electricity supply has
been switched off and that it cannot be accidentally switched on.
The electrical connection should be carried out by an authorised electrician in accordance with
local regulations.
DANGER
The motor must be earthed and connected to an external mains switch with
suitable earth leakage installed by a qualified electrician.
Detailed information about the connection of motors and, if necessary, of control and
monitoring devices can be taken from the appropriate circuit diagrams from the switch
cupboard manufacturer. So that a perfect connec tion with the least possible contact
resistance can be established when connecting the power supply lines, the conductor ends
should not be tin -plated. Should the conductor ends be tin-plated, the tin -plated ends must
be removed. The individual exposed fine-strand wires must be connected to the electrical
system by suitable terminal screws or with crimping or soldering cable lugs.
When the pump has been connected to the electricity supply, determine the correct direction of
rotation as follows. Prior to installation, manually start the pump unit for no longer than 2
seconds run time, then turn off.
If the pump has been installed, please refer to below steps to determine rotation:
1. Start the pump and check the quantity of water and head developed.
2. Stop the pump and interchange two of the phase connections. In the case of motors
wound
- for star delta starting, exchange U1 by V1 and U2 by V2.
3. Start the pump and check the quantity of water and head developed.
13
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
4. Stop the pump.
5. Compare the results taken under points 1. and 3. The connection which gives the
larger quantity of water and the higher head is the correct connection.
7.0 Start-Up
Briefly start the pump against the almost closed gate valve (open only so far that the air can
escape) and compare the attained delivery head against the manufacturer’s specifications.
Then open the gate valve until the operating point is reached. When the values for delivery flow
and delivery head are significantly lower, an incorrect direction of rotation may be the cause. In
such a case, 2 phases of the power cable must be swapped. Normally, the pump reaches its
highest pressure with the gate valve closed and while rotating in the correct direction.
The unit must not be driven longer than 3 minutes in the wrong direction.
If there are impurities in the water or if it is a newly drilled well, the valve should be opened
gradually as the water becomes clearer. The pump should not be stopped until the water is
completely clean, as otherwise the pump parts and the non-return valve may choke up.
Opening the slide valve gradually, watch the current consumption of the motor on the ammeter
as also check the drawdown of the water level to ensure that the pump always remains
submerged. Slowly open the slide valve until the ammeter shows the operational current
according to the data sheet. When the operating point has been reached for which the pump
unit was designed, current consumption must approximately coincide with that given in the
data sheet. If this is not the case, the fitting conditions and electrical connections must once
again be checked. If there are no abnormalities during and after the test run, the pressure pipe
can be connected if this has not yet been accomplished.
The dynamic water level should always be above the suction motor adaptor
of the pump.
If the pump can pump more than yielded by the well, it is recommended to fit a control unit of
dry-running protection. If no water level electrodes or level switches are installed, the water
level may be drawn down to the suction motor adaptor of the pump and the pump will then
draw in air. Long time operation with water containing air may damage the pump and cause
insufficient cooling of the motor.
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
14
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
8.0 Maintenance/Servicing
8.1 Pump unit
While K.S.P. submersible pumps do not require regular maintenance, it is a good practice to
monitor the conditions and performance of the pump and motor. If a pump unit should stand
idle for a longer period of time, perform a 10 minute test run every 2-3 months, so that
malfunctions can be recognized in time.
The pump unit must be completely submersed in pumping medium for this
test run.
This diagnosis may be carried out by checking the maximum pressure (shut valve for a very
short period) generated by the pump, and by checking the amperage draw of the motor at
standard duty flow rate. Both these figures should be compared to pressures and current
draws recorded when the unit was initially installed. Any reduction in pressure may indicate
wear in the pump, while any increase in motor current indicates a possible overload condition.
Consult the pump service chart for further diagnosis of possible causes.
8.2 Electrical system
All the work on the electrical system may only be performed by qualified
electricians!
8.3 Removal
If the pump unit is equipped with a non-return valve, the unit weight with the
ascending pipelines and the water column contained within it must be lifted
during removal.
8.4 Notes of disassembly and assembly
Only qualified personnel may disassemble and assemble the pump as shown
in the sectional drawings (ref. to section 10.0). The order of the steps can be
deriving from the sectional drawings or can be requested from the
manufacturer.
15
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
9.0 Operating problems and their elimination
Fault
Probable cause
1. The pump does not start a) The fuses are blown
b) Motor protection
triggered
c) No electricity spply
d) The motor starter
overload has tripped out
e) Motor starter/contactor
is difective
f) Starter device is defective
g) The control circuit has
been interrupted or is defective
h) The dry-running protection has cut off the electricity supply to the pump,
due to low water level
i) The pump submersible
drop cable is defective
2. The pump runs but
a) The discharge valve is
gives no water
closed
b) No water or too low
water level in borehole
c) The non-return valve is
stuck in its shut position
d) Blocked pump
e) The pump is defective
3. Flow inadequate
a) The drawdown is larger
than anticipated
b) Incorrect rotating direction
c) The valves in the discharge pipe are partly closed/
blocked
d) The discharge pipe is
partly choked by impurities
e) The non-return valve of
the pump is partly blocked
f) The pump and the riser
pipe are partly choked by
impurities
g) The pump is defective
h) Pressure pipe leak
i) The riser pump is defective
k) Rotating speed too low
4. Unit runs but does not a) Head too great
pump
b) Motor runs but pump
does not turn
Probable remedy
Replace the blown fuses. If the new onew blow too, the electric
installation and the submersible drop cable should be checked
Find cause for triggering, rectify and reset motor circuit breaker
Contact the electricity supply authorities
Reset the motor starter overload (auto-matically or possibly
manually). If it trips out again, chek the voltage. Is the voltage
OK, see items e) - h)
Replace the motor starter/contactor
Repair/replace the starter device
Check the electric installation
Check the water level. It is OK, check the water level electrodes/level switch
Repair/replace the pump’s cable
Open the valve
See item 3a)
Pull out the pump and clean or replace the valve
Pull out the pump and clean the strainer
Repair/replace the pump
Increase the installation depth of the pump, throttle the pump
or replace it by a smaller model to obtain a smaller capacity
Change direction of rotation
Check and clean/replace the valves, if necessary
Clean/replace the discharge pipe
Pull out the pump and check/replace the valve
Pull out the pump. Check and clean or replace the pump, if
necessary. Clean the pipes
Repair/replace the pump
Check and repair the pipework
Replace the riser pipe
Check system voltage and frequency
Reduce head
Pull out the pump, check/replace pump's coupling, if necessary
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
16
art for life
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
9.1 Checking of motor and cable
1. Supply voltage
Measure the voltage between
the phases by mean of a
voltmeter. Connect the voltmeter to the terminals in the
motor starter
2. Current consumption
Measure the amps of each
phase while the pump is
operating at a constant discharge head (if possible, at
the capacity where the motor is most heavily loaded).
The voltage should, when the motor is loaded, be within the
specified range. The motor may burn if there are larger variations in voltage. Large variations in voltage indicate poor electricity supply and the pump should be stopped until the defect has
been remedied
On three-phase motors, the difference between the current in
the phase with the highest consumption and the current in the
phase with the lowest consumption should not exceed 5 %.
If so, or if the current exceeds the full load current, there are the
following possible faults:
• The contacts of the motor starter burnt. Replace the contacts
or the control box for single-phase operation
• Poor connection in leads, possibly in the cable joint. See
item 3
• Too high or too low supply voltage. See item 1
• The motor windings are short-circuited or partly disjointed.
See item 3
• Damaged pump is causing the motor to be overloaded. Pull
out the pump for overhaul
• The resistance value of the motor windings deviates too
much (three-phase). Move the phases in phase order to a
more uniform load. If this does hot help, see item 3
Items 3 and 4: Measurement is not necessary when the supply voltage and the current consumption are
normal
3. Winding resistance
Disconnect the submersible For three-phase motors, the deviation between the highest
drop cable at the motor
and the lowest value should not exceed 5 %. If the deviation
starter. Measure the winding is higher, pull out the pump. Measure motor, motor cable
resistance between the
and drop cable separately, and repair/replace defective parts
leads of the drop cable
4. Insulation resistance
Disconnect the submersible If the insulation resistance is less than 0,5 MΩ, the pump
drop cable at the motor
should be pulled out for motor or cable repair. Local regulastarter. Measure the
tions may specify other values for the insulation resistance
insulation resistance from
each phase to earth (frame).
Make sure that the earth
connection is made
carefully
17
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
10.4 Submersible pump P6 (with thread connection)
Pos.
Code
1
02.95.01
2
16.95.03
3
07.95.05
4
5
5a
6
03.66.01
03.65.01
Stainless steel
Ressort
Acier inox
Non-return valve
Bronze
Soupape du clapet
Bronze
Wear ring
Rubber
Bague d'usure
Caoutchouc
Diffuser
Cast iron
Diffuseur
Fonte
Diffuser
Cast iron
Diffuseur
Fonte
Impeller / Roue 656
Impeller / Roue 660
04.80.05
Impeller / Roue 670
9
15.25.03
10
05.25.05
15
Fonte
Spring
04.81.05
17.08.03
14
Cast iron
04.83.05
8
13
Valve casing
Corps du clapet
Impeller / Roue 645
13.25.10
12
Denomination
04.82.05
7
11
21
17.02.09
Designation
17.03.09
01.65.01
18.95.03
25.44.03
21.00.03
Bronze / Bronze
Shaft
Chrome steel
Arbre
Acier chrome
Bearing
Stainless Steel-Rubber
Palier corps d'etage
Acier inox-Caoutchouc
Screw
Stainless steel
Vis
Acier inox
Bushing
Bronze
Douille conique
Bronze
O.Ring
Rubber
Bague O.R.
Caoutchouc
Suction casing
Cast iron
Corps d'aspiration
Fonte
Coupling
Stainless steel
Accouplement
Acier inox
Strainer
Stainless steel
Crepine d'aspirant
Acier inox
Cable guard
Stainless steel
Gaine du câble
Acier inox
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
10.5 Submersible pump P6 (with flange connection)
Pos.
1
2
Code
02.22.01
16.95.03
3
07.95.05
4
17.02.09
5
03.66.01
5a
03.65.01
6
7
8
9
Cast iron
Corps du clapet
Fonte
Spring
Stainless steel
Ressort
Acier inox
Non-return valve
Bronze
Soupape du clapet
Bronze
Wear ring
Rubber
Bague d'usure
Caoutchouc
Diffuser
Cast iron
Diffuseur
Fonte
Diffuser
Cast iron
Diffuseur
Fonte
Impeller / Roue 645
04.83.05
Impeller / Roue 656
04.81.05
Impeller / Roue 660
04.80.05
Impeller / Roue 670
13.25.10
17.08.03
15.25.03
05.25.05
11
17.03.09
12
01.65.01
13
18.95.03
15
Denomination
Valve casing
04.82.05
10
14
Designation
25.44.03
21.00.03
Shaft
Bronze / Bronze
Chrome steel
Arbre
Acier chrome
Bearing
Stainless Steel-Rubber
Palier corps d'etage
Acier inox-Caoutchouc
Screw
Stainless steel
Vis
Acier inox
Bushing
Bronze
Douille conique
Bronze
O.Ring
Rubber
Bague O.R.
Caoutchouc
Suction casing
Cast iron
Corps d'aspiration
Fonte
Coupling
Stainless steel
Accouplement
Acier inox
Strainer
Stainless steel
Crepine d'aspirant
Acier inox
Cable guard
Stainless steel
Gaine du câble
Acier inox
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
22
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
11.0 Protocols
27
water level
lowering
H4
D
minimum 1m
H2
H5
H1
H3
11.1 Installation protocol
Serial number of the pump:
H3 Depth of operating water level
m
Serial number of the motor:
m
m
H1 Well depth
m
H4 Depth of minimum water level
Distance between lower edge of
H5 motor and well bottom
H2 Installation depth
m
D Well diameter
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
m
RS6 -R8 - P6 - P8 - P10
Submersible Pumps
art for life
11.2 Commissioning protocol
1. Switch on the pump with the isolating valve opened slightly
2. Check the direction of rotation for the submersible unit and correct if necessary
3. Read the manometer:
Pressure with isolating valve closed:
bar
Pressure with isolating valve completely opened:
bar
4. Determine dimension H3 (see page 27)
Depth of operating water level
m
5. Deternine the delivery head of the pump ( =H3 + manometer reading, converted to m)
6. If the measure delivery head is lower than the requested delivery head:
Close the isolating valve somewhat (throttle)
Manometer reading after throttling:
m
7. Determine the electricl data of the motor, adjust the motor protection according to the motor manual
Current consumption L1
A L2
A L3
A
Voltage
V
Frequency
8. Start type: Direct-on-line
Hz
Autotransformer
Star-delta
9. Read/determine the operating data:
Capacity
m3/h
Water temperature
o
Sand content in the liquid
yes/no
C
10. Commisioning performed:
Date
Name
Signature
K.S.P. - Kostakis Submersible pumps - 3rd km Argous-Korinthou, PC 212 00 Argos - Phone: (+30) 2751069370 - fax: (+30)2751069371 - email: [email protected] - http://www.kspumps.gr
28
art
for
life
K.S.P. - Kostakis Submersible pumps
3rd km Argous-Korinthou, PC 212 00 Argos
Made in Greece
Phone: (+30)2751069370
Fax: (+30)2751069371
http://www.kspumps.gr
email: [email protected]